JP2017509716A - Flame retardants, heat insulation materials and surface protection agents - Google Patents

Abstract

The present invention relates to the preparation of compositions having flame retardant properties, thermal insulation properties and surface protection properties using industrial dross, aluminum dross. The composition is prepared by reacting aluminum dross particles with an acid and subjecting the resulting reaction mixture to a drying process. The compositions and those prepared from or coated with the compositions have enhanced flame retardant properties, thermal insulation properties and surface protection properties. The present invention is useful for preparing building materials for use in the building industry and for forming protective coatings.

Description

  The present invention relates to a composition prepared from aluminum dross having flame retardant properties, thermal insulation properties and surface protection properties.

  The aluminum smelting and remelting process results in many industrial wastes. Aluminum dross is a hazardous waste that remains from the melting or remelting of aluminum.

Two types of commonly occurring aluminum dross are black dross and white dross. White dross contains two major components, aluminum metal (Al (m)) and aluminum oxide, and less depending on the conditions in the furnace and subsequent drosspan, the metal source and alloy being processed An amount of other ingredients may be included. These other components include aluminum nitride (AlN), aluminum carbide (Al ₄ C ₃ ) and cryolite (NA ₃ AlF ₆ ). Cryolite is often associated with molten metal originating from the cell, and AlN and Al ₄ C ₃ are associated with thermite reaction occurring in the furnace or dross skim pan.

Aluminum dross reuse Aluminum dross has many applications in the ceramic, steel and cement industries, for example, in the steel industry, aluminum dross can be finely crushed and used as a solvent. Although various processes have been described for recovering additional Al (m) from aluminum dross, most aluminum dross applications require aluminum dross with a significant amount of Al (m).

  Alternatively, the aluminum dross is rendered neutral or inert and then disposed of as landfill waste.

  U.S. Patent No. 6,099,056 teaches a process for providing a plastic composition that adds wet phosphoric acid to aluminum dross resulting in wet coarse powder. This coarse powder is agitated until it forms a granulated product with a particle size of 1.6 mm to 2.4 mm for use as a fertilizer.

  Patent Document 2 optionally treats aluminum dross in advance to remove particle sizes greater than 0.8 mm, and cleans the dross in dilute acid for a period of about 1 hour in a (rotary) screen cleaner. And / or cyclone cleaning and harvesting the particles from the resulting aqueous solution. The particles are proposed as a medium for sandblasting. Other uses mentioned for the particles are in granulated superphosphate fertilizers and as additives / fillers in bricks including refractory bricks, paint or road materials, agricultural or household drain tiles and paints including.

  U.S. Patent No. 6,057,033 slurries aluminum dross debris (aluminum dross is crushed and screened to remove Al particles), heating and stirring the slurry, and then the slurry is 30-30 It describes the reaction with 99 wt% sulfuric acid. Next, the pressure and temperature are increased while maintaining the reaction in the liquid phase, and the reaction produces aluminum sulfate.

  U.S. Patent No. 6,057,031 describes calcination of aluminum residual ash and further proposes a product as a refractory material. Aluminum residual ash is described as a remnant produced after aluminum metal is separated from aluminum slag and treated by recycling.

Fire spread prevention In the construction industry, flame retardants are added to building materials to delay their damage in the event of a fire and to allow the building occupants to safely escape. The flame retardant can be incorporated into the composite material or applied as a coating on the surface of the building material.

US 4,475,940 NZ238178 US 4,320,098 US20050016395

  It is an object of the present invention to obtain a useful product from the remaining aluminum dross or at least to provide a useful alternative to treating the remaining dross as landfill waste.

  It is another independent object of the present invention to provide a product having flame retardant properties and / or thermal insulation properties and / or surface protection properties, or at least to provide useful options to the general user.

  In a first broad aspect, the present invention provides a method of preparing a composition having flame retardant properties, thermal insulation properties and / or surface protection properties, the method comprising reacting aluminum dross particles with an acid, and Subjecting the resulting reaction mixture to a drying process.

  In another aspect, the present invention provides flame retardant properties, thermal insulation properties and / or surface protection properties prepared by reacting aluminum dross particles with an acid and further subjecting the resulting reaction mixture to a drying process. A composition is provided.

  In another aspect, the present invention provides an article comprising a composition, wherein the composition has flame retardant properties, thermal insulation properties and / or surface protection properties, wherein the aluminum dross particles are reacted with an acid, Prepared by subjecting the resulting reaction mixture to a drying process.

  The above may be coated with the above composition or may comprise the above composition cast into a desired shape.

  In another aspect, the present invention provides a method for providing fire resistance to an object, the method being prepared by reacting aluminum dross particles with an acid and further subjecting the resulting reaction mixture to a drying process. Adding a flame retardant composition to the article.

  The drying process may be a passive process, may include an active drying process, or may be a combination of passive drying and active drying.

  In a preferred embodiment, the above is a building material.

  In another aspect, the present invention provides the use of a reaction product of aluminum dross particles and acid to prepare a composition having flame retardant properties, thermal insulation properties and / or surface protection properties.

  Preferably, the aluminum dross particles have a size of 2 mm or less.

  Preferably, the amount of liquid in the reaction mixture is 50 to 1000 mL per kg of dross, more preferably 100 to 350 mL per kg of dross.

  The aluminum dross particles and acid are preferably reacted by mixing for 10-15 minutes. The reaction may reach a temperature in the range of 50-90 ° C, such as a temperature in the range of 65-75 ° C.

  Preferably, the acid is a mineral acid such as phosphoric acid. Preferably, the acid has a concentration of at least 50 w / w%.

  The reaction mixture may optionally be added to the object before it is subjected to a drying process, for example by spraying, troweling, molding or forming. Preferably, the reaction mixture is passively dried. The drying process may occur for at least 12 hours, such as for at least 24 hours.

FIG. 5 is a series of sequential fire tests of a gypsum board (left) coated with the composition of the invention described in Example 3 versus a control gypsum board (right). FIG. 5 shows a propane burner burn test of MDF (left) coated with the composition of the present invention described in Example 4 versus a control medium density fiberboard (MDF) (right). Combustion test of wool polyester ceiling insulation (left) injected with the composition of the invention described in Example 5 versus control wool polyester ceiling batt (right) was shown. FIG. FIG. 7 shows a burn test of a polystyrene block (left) coated with the composition of the invention described in Example 6 versus a control polystyrene block (right). FIG. 8 shows a scheme for a combustion test of a steel sheet to which a composition of the invention has been applied, including the thermal couple used to record the heat transfer described in Example 7. It is the figure which showed the result with respect to the combustion test of the steel plate to which the composition of this invention described in Example 7 was adhered.

  White dross is caused by furnace skimming during the aluminum smelting process. White dross may contain oxidizing compounds that are introduced during the treatment process rather than being formed directly in the furnace. White dross typically does not contain salt flux.

  In an exemplary hot dross process, the dross is skimmed into a dross bucket, which is then subjected to a rotating process. Next, (Al (m)) is recovered from the dross bucket and further overflows into the water collection saw. Next, the remaining dross with the lesser amount (Al (m)) is placed aside and allowed to cool.

  Upon cooling, the dross is easily destroyed using a cold dross process. This can be done by various mechanical processes. At this stage, the remaining negatively charged (Al (m)) can be separated from the aluminum dross using an eddy current separator. Next, the treated dross with further (Al (m)) depletion is recovered, which can have a particle size of up to 10-15 mm. Dross processed using an eddy current separator needs to be crushed and generally does not need to be processed twice in an eddy current separator, but in some cases this may be required.

  Since the mechanical process essentially produces a powder, the dross powder can also be recovered using baghouse filtration to recover air-borne dross particles.

  Black dross is mechanically processed in the same manner as white dross, but when dross comes from the furnace, it is cooled and, further, at the stage of remelting, typically occurring in a rotary furnace, Salt is added. This recovery is called the mirabilite process and makes dross very toxic. However, in some processes, such as those used by Weston Aluminum, Inc., Australia, the mirabilite is then washed. The mirabilite may retain salt even after the cleaning process.

  The present invention involves the reaction of aluminum dross particles with an acid to produce a reaction mixture that can be used to form a flame retardant and insulating product.

  It is advantageous to use white dross in the present invention. The use of black dross does not result in the same intense exothermic reaction. However, the reaction can be achieved using black dross by adding substantially more acid. The strength of the reaction can affect the porosity and structural integrity of the dried composition.

  Aluminum dross particles useful in the process of the present invention may have a particle size ranging from greater than 10 mm to less than 1 mm. The use of aluminum dross having a particle size of 10 mm or less, especially 2 mm or less, has been found to be particularly useful in the present invention. The aluminum dross particles can be sized by any means known in the art. For example, the dross can be screened by air scrubbing or can be screened using a kitchen strainer or other suitable eye strainer to achieve the desired particle size, or a shaking table or ore screen can be used. Can be used.

Definitions As used herein, the term “aluminum dross” means a byproduct of an aluminum melt smelting or remelting process.

  As used herein, the term “reaction mixture” means a mixture of aluminum dross and acid in its plastic or pre-dried state.

  As used herein, the term “dried composition” means the reaction product of aluminum dross and acid in its dry state.

  The inventor has discovered that by reacting aluminum dross particles with an acid, a composition having excellent flame retardant, thermal insulation and surface protection properties can be produced.

Acid Preferably, the acid is a mineral acid. While phosphoric acid is preferred, it will be appreciated that other acids such as nitric acid, hydrochloric acid and sulfuric acid may be used. The acid utilized may advantageously be at a concentration of 50% w / w or higher, such as 80% w / w or higher or 90% w / w or higher.

Reaction mixture Typically, the reaction mixture may be prepared by combining aluminum dross particles with an acid. Optionally, the aluminum dross particles can be first sized before being combined with the acid. Optionally, the aluminum dross particles can be first moistened with water before the acid is added. Advantageously, the liquid volume of the reaction mixture is 50-550 mL per kg dross, such as 100-350 mL per kg dross.

  When mixed, a spontaneous exothermic reaction occurs. The reaction may be active and may cause an increase at a temperature of 50-90 ° C. This reaction may proceed for several minutes before slowing down.

  Optionally, prior to the drying process, the reaction mixture can be applied as a coating to a surface where enhanced flame retardancy or thermal insulation is desired. Alternatively, the reaction mixture may be allowed to settle in a reaction vessel or mold of the desired shape.

  The reaction mixture is held in the reaction mixture passively by allowing water to evaporate from the reaction mixture, or by applying warm air, for example by using a hair dryer or soft frame, over the reaction mixture. It will be appreciated that it can be actively dried by evaporating the water that has been removed. During drying, the reaction mixture is not stirred or disturbed. Drying of the reaction mixture may occur for several hours, for example 12 hours, 24 hours or 48 hours.

Application of the reaction mixture as a coating If it is desired to apply the reaction mixture as a coating to the surface, the reaction mixture can be applied using a number of means including a robust spraying device, troweling, casting and molding. Can do. Although the reaction mixture is “self-prime”, meaning that surface treatment of the substrate is not necessary, the surface to which the reaction mixture is applied is pre-treated by random cutting, polishing or sand blasting. It will be correctly understood that it can be processed. In addition, the surface can be treated by adding a binder or adhesive to the surface prior to application of the reaction mixture. For example, rubberized binders can be used for flexibility and to improve the adhesion of the reaction mixture to the surface.

Additional coatings Optionally, additional coatings can be added to the dried composition to seal the product and make it weatherable, resulting in a significant improvement in surface tension.

  In one embodiment, the additional coating can provide additional fire protection. For example, the further coating can be a foamable fireproof paint. For example, the additional coating can be a fire resistant acrylic envelope, such as CAP508 produced by CAP Coatings Australia.

  In one embodiment, the further coating may be an acrylic water based paint such as that produced by Vipond's Paints Australia. Optionally, two coatings of acrylic water-based paint can be applied. Acrylic aqueous paint coating is a cost-effective means of sealing high quality, dry compositions. Acrylic coatings are preferred because they have fewer harmful environmental impacts than other coating options. In addition, the acrylic coating easily bonds to the dried composition without the need for surface treatment, and further provides structural integrity, surface flexibility and waterproofness.

  Optionally, a primer such as an acrylic metal primer can be added to the substrate prior to application of the reaction mixture, particularly when the substrate is a metal. The primer can contribute to avoiding any shock rust reaction that can occur as a result of adding an aqueous system to the metal.

Uses and Products The reaction mixture can be adapted to many useful products.

  In one embodiment, the composition can provide high fire resistance to industrial steel, oil and gas ships in various applications including but not limited to structural steel. For example, the composition can provide pipe protection, tank protection, electrical panel protection and engine room protection.

  In addition, the composition can be used as an antirust or sealing coating. Surface protection of the surface damaged by rust can be achieved by applying the composition to rusting surfaces such as corrugated iron roofs. The composition seals rust, prevents further oxidation and fills rust holes. The composition can also act to seal the surface against degradation. For example, application of the composition to an asbestos-containing substrate can prevent surface degradation and asbestos particle migration. The composition also acts to insulate the surface.

  It is also possible to decant a higher purity liquid from the reaction mixture to produce a malp (heavy paint). Malp can be applied to various surfaces, for example, with a brush or roller. Malp is also self-contained with strong adhesive properties and does not allow any flame propagation even when covered by a waterproof coating.

  It will be appreciated that when coating the material to achieve improved fire resistance, the resulting fire resistance depends on the thickness of the coating. As a result, the thickness of the applied coating can be adjusted to achieve the desired fire resistance. For example, the coating thickness for Malp can be in the range of 1-10 mm, such as 3 mm. As is known in the art, the coating thickness for a paint can be in the micron thickness range. Since the coatings, malp and paint are self-contained, it is not necessary to treat the surface before application.

  The reaction mixture can also be cast into the desired shape and dried to produce a refractory block. The block so generated reflects heat and thus provides a cold walking surface as a thermal insulator, for example as a refractory brick in the furnace and furnace lining, or in areas that receive a lot of solar radiation. Also useful in

  Although the process of the present invention has the ability to produce solid blocks of dry composition, as described in detail below, lime and cement are also used in the furnace and furnace lining. It is envisioned that it can be incorporated into dry compositions for use in the range of castable to refractory bricks.

  The dried composition block is processed into a powder or granule and, as a suspended substance, in a paint or other protective coating to enhance the thermal rating and fire resistance of the paint, coating or building material. It can be added or incorporated into existing building materials such as gypsum boards.

  That the reaction mixture can be injected into a porous material such as cloth and insulated wool and then the porous material can be dried to provide enhanced fire resistance to the porous material. Will also be shown.

  The invention will now be described with reference to the following non-limiting examples.

Preparation of the reaction mixture 2 kg of white aluminum dross with an average particle size of 4 mm was obtained from Weston Aluminum Australia. The dross was sized by passing it through a kitchen strainer and then placed in a large mixing bowl and further moistened with a small amount of water. The generation of ammonia gas was observed. It is also expected that other gases will be released by dross exposure to water.

  Next, 250 grams of phosphoric acid (food grade 80% w / w) was immediately added and the ingredients were mixed with a trowel to form a reaction mixture. Within the first 30 seconds after the acid was added, an exothermic reaction between aluminum dross and acid raised the temperature and produced more hydrogen sulfide gas. The reaction mixture was then thoroughly mixed so that the acid was in contact with all of the materials in the mixing bowl. The foaming of the material started within 1 minute, and the vapor generated from the mixing bowl could be seen.

Preparation of Malp Black aluminum dross was obtained from Australia (Weston Aluminum). The particle size was reduced by passing through a wheat strainer. 1 kg of aluminum dross was moistened using 130 mL of water. Next, 120 mL of 80% food grade phosphoric acid was added and further stirred until it became liquid. The exothermic reaction was virtually immediate. Stirring was continued to ensure that the acid was in contact with all of the dross. The hot smell of hydrogen sulfide was recognized as being released from the exothermic reaction.

  A significant increase in the temperature of the composition began to occur after 3 minutes. Stirring was continued for an additional 3 to 4 minutes before an additional 250 mL of water was added to achieve a dark paint concentration.

Gypsum Board The Malp prepared in Example 2 was applied to a gypsum board (standard 5 mm Gib® board) using paint brush. No surface treatment was used on the gypsum board, but Malp bonded well. When placed on a gypsum board, the exothermic reaction slowed dramatically. A further coating of the composition was applied to bring the coating to a coating thickness of about 0.75 mm. This was dried overnight.

  The next morning, flame propagation and destruction tests were performed using a propane gas burner. This mechanism is illustrated in FIG. The propane torch was concentrated on the board at a distance of about 20 mm for 4 to 5 minutes. The oxygen acetylene torch was then concentrated on the composition and the temperature was increased for an additional 3 minutes. A control sample of uncoated gypsum board (control sample) was subjected to the same process.

result:
No ignition of the dried composition or the underlying gypsum board was observed. Some discoloration or blistering appeared to occur for the dried composition, using an ultra-high temperature estimated to exceed 1000 ° C. However, the dried composition still remained.

  The uncoated gypsum board (control sample) disappeared within 60 seconds with significant flame propagation and was later destroyed by the flame.

  Ten minutes after the start of the burning test, the area immediately behind the place where the flame was collected on the gypsum board was warm enough to be touched by hand. There was no further effect on the gypsum board and the dried composition remained bonded to the gypsum board throughout the test.

  Thus, a coating of a composition with a thickness of less than 1 mm provided gypsum board protection, no flame propagation was observed, and no further penetration of the gypsum board or disappearance of the dried composition was observed. Throughout the test, the back of the gypsum board was warm enough to be touched by hand.

MDF
The reaction mixture prepared as described in Example 1 was applied as a 4 mm coating to medium density fiberboard (MDF) without any prior treatment of MDF. The coating was dried for 12 hours. FIG. 2 shows a combustion test in which no fire spread occurred.

A wool polyester ceiling insulation reaction mixture was prepared as described in Example 1. When the exothermic reaction was in progress, 250 mL of water was added to delay the exothermic reaction but never stopped it. The end of the wool insulation was repeatedly dipped into the reaction mixture to produce a coating. The coating was given 12 hours to dry and a burn test was performed as shown in FIG. The control wool insulation smoked and charred, and the injected wool insulation enhanced resistance to the burner.

  If the particle size of the material is significantly small, the material can simply be sprayed onto the surface to form a protective coating, or the use of smaller particle size can allow improved fiber penetration This is envisioned.

Polystyrene block The reaction mixture was prepared as described in Example 1 and further applied by troweling to a 60 mm polystyrene board with a 3 mm thick coating. The coating was given 12 hours to dry and a flammability test was performed as shown in FIG. A control sample of polystyrene not protected by the coating of the present invention melted rapidly under the flame, while the polystyrene board protected by the coating of the present invention remained intact.

Cement mixing block with steel backing The reaction mixture was prepared as described in Example 1 and further poured into a mold constructed to a predetermined size of polycarbonate plastic. Although the mold had a thickness of 28 mm, any desired size or shape of mold could be formed for use in this aspect of the invention, up to 300 mm or more depending on the desired fire resistance. It will be appreciated that it includes a mold having a thickness. The reaction mixture flowed reasonably flat and was flattened using handtrowells to give a uniform thickness in the mold.

  The reaction mixture not only continued to react in the mold for a few minutes to produce steam, but also released hydrogen sulfide. When the reaction was visibly seen as slow in the mold, further hand troweling was required to give a uniform thickness. The exposed surface was then bumpy with a trowel to provide a binding surface. Within 10 minutes, the reaction mixture was partially dried.

  The dried composition was left in the mold overnight at a room temperature of 24 ° C. and then removed from the mold to form a block and allowed to dry for an additional 24 hours. The dried composition was similar to ceramics, and when patted, a crisp ceramic sound could be heard. Next, two overcoats of urethane acrylic aqueous paint (Vipond's Paints Australia) were applied directly to the dried composition, and no undercoat or surface treatment was required. Next, the painted surface was dried.

  Observation of the dried composition showed that the material structure was similar to the preformed cement block and had small and consistent voids throughout its surface. A detailed examination of the block showed that these voids continued throughout the dried composition.

  In a bond test demonstrating an immediate bond between the acrylic paint and the reaction mixture, a thin coating of additional reaction mixture was coated directly on one third of the surface of the block and had a thickness of less than 1 mm. This thin coating was produced from white dross obtained from Weston Aluminum Australia passed through a kitchen strainer using the same water and phosphoric acid mixing process as described above. A thin coating of the reaction mixture was simply brushed on the surface of the painted block, and the whole was dried overnight.

  A coating of the reaction mixture was applied to the steel plate and further dried for 12 hours. Next, a 4 mm coating was added to the binding surface of the block and then the pre-coated steel plate was placed on top with a small weight to prevent it from moving. The whole was then dried, further providing a secure bond.

result:
A thermal bond was placed on the front of the block and another thermal bond was placed just behind the spot where the flame would hit the front. Thermal bonds T1 (previous bond) and T2 (back bond) were placed in a consistent manner under pressure on the surface where the reading was taken. Therefore, the distance between the two thermal bonds was the thickness of the block and the steel plate. A propane torch was placed within 50 mm of the front, just where the previous thermal bond was placed. The heat transfer through the block was recorded and the result is shown in FIG. The chevron of the data at about 2.30 pm, 3 pm and 4.50 pm indicates heat source replacement or repositioning.

  Combustion tests showed that there was a very slow heat transfer despite the frontal heat reaching temperatures above 1000 ° C. The front surface burned red and no visible structural degradation of the surface material was observed, despite what was called blast heat was applied. The maximum temperature recorded on the front side was 1107 ° C. and the maximum temperature recorded on the back side was 98 ° C. (FIG. 6).

  Although gas evolution during this process is expected, no gas was observed to be released.

Although the present invention has been described with reference to particular embodiments and examples, it will be appreciated by those skilled in the art that the present invention may be embodied in many other forms.

Claims (82)

  A method of preparing a composition having flame retardant properties, comprising reacting aluminum dross particles with an acid and subjecting the resulting reaction mixture to a drying process.   The method of claim 1, wherein the drying process is a passive process, an active drying process, or a combination of a passive drying process and an active drying process.   The method according to claim 1, wherein the aluminum dross particles have a size of 2 mm or less.   The method according to any one of claims 1 to 3, wherein a liquid amount of the reaction mixture is 50 to 1000 mL per 1 kg of dross.   The method according to any one of claims 1 to 4, wherein a liquid amount of the reaction mixture is 100 to 350 mL per 1 kg of dross.   The method according to claim 1, wherein the aluminum dross particles and the acid are reacted by mixing for 10 to 15 minutes.   7. A process according to any one of the preceding claims, wherein the reaction reaches a temperature in the range of 50-90C.   8. A method according to any one of the preceding claims, wherein the reaction reaches a temperature in the range of 65-75 [deg.] C.   The method according to any one of claims 1 to 8, wherein the acid is a mineral acid.   The method according to any one of claims 1 to 9, wherein the acid is phosphoric acid.   11. A method according to any one of the preceding claims, wherein the acid has a concentration of at least 50 w / w%.   12. A method according to any one of the preceding claims, wherein the reaction mixture is added to an object before being subjected to the drying process.   13. A method according to claim 12, wherein the reaction mixture is added by spraying, troweling, molding or forming.   14. The method according to any one of claims 1 to 13, wherein the reaction mixture is passively dried.   15. A method according to any one of the preceding claims, wherein the drying process occurs over at least 12 hours.   16. A method according to any one of the preceding claims, wherein the drying process occurs over at least 24 hours.   17. A method according to any one of the preceding claims, wherein the composition has thermal insulation properties and / or surface protection properties.   A composition having flame retardant properties, prepared by reacting aluminum dross particles with an acid and further subjecting the resulting reaction mixture to a drying process.   19. The composition of claim 18, wherein the drying process is a passive process, an active drying process, or a combination of a passive drying process and an active drying process.   The composition according to claim 18 or 19, wherein the aluminum dross particles have a size of 2 mm or less.   21. A composition according to any one of claims 18 to 20, wherein the liquid volume of the reaction mixture is 50 to 1000 mL per kg of dross.   The composition according to any one of claims 18 to 21, wherein the liquid amount of the reaction mixture is 100 to 350 mL per kg of dross.   23. A composition according to any one of claims 18 to 22, wherein the aluminum dross particles and the acid are reacted by mixing for 10-15 minutes.   24. A composition according to any one of claims 18 to 23, wherein the reaction reaches a temperature in the range of 50-90C.   25. A composition according to any one of claims 18 to 24, wherein the reaction reaches a temperature in the range of 65-75 [deg.] C.   26. A composition according to any one of claims 18 to 25, wherein the acid is a mineral acid.   27. A composition according to any one of claims 18 to 26, wherein the acid is phosphoric acid.   28. A composition according to any one of claims 18 to 27, wherein the acid has a concentration of at least 50 w / w%.   29. A composition according to any one of claims 18 to 28, wherein the reaction mixture is added to an object prior to being subjected to the drying process.   30. The composition of claim 29, wherein the reaction mixture is added by spraying, troweling, molding or forming.   31. A composition according to any one of claims 18 to 30, wherein the reaction mixture is passively dried.   32. A composition according to any one of claims 18 to 31, wherein the drying process occurs over at least 12 hours.   33. A composition according to any one of claims 18 to 32, wherein the drying process occurs over at least 24 hours.   34. A composition according to any one of claims 18 to 33 having thermal insulation properties and / or surface protection properties.   A composition comprising a composition having flame retardant properties, prepared by reacting aluminum dross particles with an acid and further subjecting the resulting reaction mixture to a drying process. .   36. The article of claim 35, wherein the drying process is a passive process, an active drying process, or a combination of a passive drying process and an active drying process.   37. The article of claim 35 or 36, coated with the composition.   38. The article of claim 37, wherein the reaction mixture is added by spraying, troweling, casting or forming.   37. The article of claim 35 or 36 comprising the composition cast into a desired shape.   40. An article according to any one of claims 35 to 39, which is a building material.   41. The article according to any one of claims 35 to 40, wherein the aluminum dross particles have a size of 2 mm or less.   42. A product according to any one of claims 35 to 41, wherein the liquid volume of the reaction mixture is 50 to 1000 mL per kg of dross.   43. A product according to any one of claims 35 to 42, wherein the amount of liquid in the reaction mixture is 100 to 350 mL per kg of dross.   44. The article of any one of claims 35 to 43, wherein the aluminum dross particles and the acid are reacted by mixing for 10-15 minutes.   45. An article according to any one of claims 35 to 44, wherein the reaction reaches a temperature in the range of 50-90C.   46. The article according to any one of claims 35 to 45, wherein the reaction reaches a temperature in the range of 65-75 [deg.] C.   47. An article according to any one of claims 35 to 46, wherein the acid is a mineral acid.   48. An article according to any one of claims 35 to 47, wherein the acid is phosphoric acid.   49. An article according to any one of claims 35 to 48, wherein the acid has a concentration of at least 50 w / w%.   50. An article according to any one of claims 35 to 49, wherein the reaction mixture is passively dried.   51. An article according to any one of claims 35 to 50, wherein the drying process occurs over at least 12 hours.   52. The article of any one of claims 35 to 51, wherein the drying process occurs over at least 24 hours.   53. Article according to any one of claims 35 to 52, wherein the surface is protected from corrosion and / or degradation.   54. The article according to any one of claims 35 to 53, which is thermally insulated by the composition.   A method of providing fire resistance to an article, wherein a flame retardant composition prepared by reacting aluminum dross particles with an acid and subjecting the resulting reaction mixture to a drying process is added to the article. A method comprising steps.   56. The method of claim 55, wherein the drying process is a passive process, an active drying process, or a combination of a passive drying process and an active drying process.   57. A method according to claim 55 or 56, wherein the aluminum dross particles have a size of 2 mm or less.   58. A method according to any one of claims 55 to 57, wherein the amount of liquid in the reaction mixture is 50 to 1000 mL per kg of dross.   59. A method according to any one of claims 55 to 58, wherein the amount of liquid in the reaction mixture is 100 to 350 mL per kg of dross.   60. A method according to any one of claims 55 to 59, wherein the aluminum dross particles and the acid are reacted by mixing for 10-15 minutes.   61. The method according to any one of claims 55 to 60, wherein the reaction reaches a temperature in the range of 50 to 90 <0> C.   62. The method according to any one of claims 55 to 61, wherein the reaction reaches a temperature in the range of 65-75 [deg.] C.   63. A method according to any one of claims 55 to 62, wherein the acid is a mineral acid.   64. A method according to any one of claims 55 to 63, wherein the acid is phosphoric acid.   65. A method according to any one of claims 55 to 64, wherein the acid has a concentration of at least 50 w / w%.   66. A method according to any one of claims 55 to 65, wherein the reaction mixture is added by spraying, troweling, molding or forming.   67. A method according to any one of claims 55 to 66, wherein the reaction mixture is passively dried.   68. A method according to any one of claims 55 to 67, wherein the drying process occurs over at least 12 hours.   69. A method according to any one of claims 55 to 68, wherein the drying process occurs over at least 24 hours.   70. A method according to any one of claims 55 to 69, which provides thermal insulation and / or surface protection for the composition.   Use of a reaction product of aluminum dross particles and an acid to prepare a flame retardant composition.   Use of the reaction product of aluminum dross particles and acid to prepare a thermal insulation composition.   Use of a reaction product of aluminum dross particles and an acid to prepare a surface protection composition.   74. Use according to any one of claims 71 to 73, wherein the aluminum dross particles have a size of 2 mm or less.   75. Use according to any of claims 71 to 74, wherein the reaction product is prepared from a reaction mixture having a liquid volume of 50 to 1000 mL per kg of dross.   76. Use according to any one of claims 71 to 75, wherein the reaction product is prepared from a reaction mixture having a liquid volume of 100 to 350 mL per kg of dross.   77. Use according to any one of claims 71 to 76, wherein the reaction product is prepared from a reaction mixture mixed for 10-15 minutes.   78. Use according to any of claims 71 to 77, wherein the reaction product is prepared from a reaction mixture that has reached a temperature in the range of 50-90C.   79. Use according to any of claims 71 to 78, wherein the reaction product is prepared from a reaction mixture that has reached a temperature in the range of 65-75C.   80. Use according to any one of claims 71 to 79, wherein the acid is a mineral acid.   81. Use according to any one of claims 71 to 80, wherein the acid is phosphoric acid.   82. Use according to any one of claims 71 to 81, wherein the acid has a concentration of at least 50 w / w%.

Images